Radiant heating assembly and method of operating the radiant heating assembly

ABSTRACT

A radiant heating assembly includes a fuel valve, a blower, a controller configured to control the fuel valve and the blower, and a heat exchanger or burner tube having integrated baffle elements. Baffle elements can be integrated externally into the walls of a heat exchanger or burner tube to baffle internally of the heat exchanger.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patentapplication 61/925,953, filed Jan. 10, 2014, the advantages are herebyincorporated by reference in entirety.

BACKGROUND

1. Field of the Invention

The subject invention generally relates to a radiant heating assembly aswell as a method of operating the radiant heating assembly and method ofmanufacturing a radiant heating assembly utilizing an integrated baffletechnology in the heating tubes of the assembly.

2. Description of the Related Art

Radiant heaters are widely utilized for a variety of heating purposes.One common type of radiant heater is a radiant tube heater including aburner and a heat tube extending from the burner. In the radiant tubeheater, a gas valve provides gas into the burner while a blower motorprovides air to the burner. The gas and the air are typically mixed andignited in the burner. A flame and/or heated exhaust may pass from theburner to the heat tube such that the radiant tube heater emits radiantheat.

Attempts have been made in developing tubes for radiant tube heaters toimprove control over the flow characteristics in the heater tube.Baffles have been inserted in some instances to perform such regulation.Although such systems allow variations to the rates of the aircharacteristics through the tube, such systems involve adding elementsin the construction process.

The radiant tube heater may be installed at various different heightsabove a floor or subjected to a wide variety of environmentalconditions. Additionally, users of the radiant tube heater may desire abalanced distribution of heat across a length of the heat tube byselectively increasing blower speed to force the air quickly across thelength of the heat tube. Alternatively, users may desire to operate theradiant tube heater in a more thermally efficient manner by selectivelyreducing input of air and gas into the burner.

Accordingly, there remains an opportunity to provide a radiant tubeheater that beneficially addresses the deficiencies set forth above. Inother words, there remains an opportunity to provide a radiant tubeheater which affords selective control over variable rates of the air inthe heater tube without additional baffles to be added duringinstallation. Specifically, there remains an opportunity to provide aradiant heater tube which affords selective control over baffles tomaintain control of rates and flow characteristics of the air in theheater tube. Furthermore, there remains an opportunity to provide aradiant tube heater which exhibits increased operational efficiency overconventional modulating systems.

SUMMARY

The present invention includes a method of operating a radiant heatingassembly. The radiant heating assembly includes a fuel valve and ablower. The radiant heating assembly may include a controller configuredto control at least one of the fuel valve and the blower according toone of a plurality of algorithms corresponding to one of a plurality ofselectable modulation modes. The radiant heating assembly includes aninterface in communication with the controller which may include thestep of selecting one of the plurality of selectable modulation modesfrom the interface, and the step of modulating at least one of the fuelvalve and the blower by the controller according to the one of theplurality of algorithms corresponding to the one of the plurality ofselectable modulation modes selected from the interface.

An improved radiant heating assembly tube baffle and system is describedhere. The radiant heating assembly includes the burner for receiving theair and the fuel for combustion. The radiant heating assembly includesthe elongated heat exchanger in communication with the burner. Theradiant heating assembly includes the fuel valve for providing the fuelto the burner. The radiant heating assembly includes the blower forproviding the air to the burner. The radiant heating assembly includesthe controller configured to control the amount of the air and the fuelprovided to the burner by modulating at least one of the fuel valve andthe blower according to one of the plurality of algorithms correspondingto one of the plurality of selectable modulation modes. The radiantheating assembly includes the interface in communication with thecontroller. The one of the plurality of selectable modulation modes maybe selectable from the interface.

The radiant heating assembly advantageously provides heating tubeshaving dimples or depressions in the burner tubes, replacing theseparate baffles of the prior art that were inserted into the burnertube. The dimples or depressions are coordinated along the burner tubeto provide the same or improved flow characteristics over the prior artbaffles. In addition, the dimples or depressions in the burner tubes canbe selectively placed for selective control of flow characteristicswhich, in turn, can be used to control other characteristics of theburner tube and the heater in general.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated,as the same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1 is a perspective view of a prior art radiant heating assemblyincluding an elongated heat exchanger and a housing;

FIG. 2 is a perspective view, partially in phantom, of the radiantheating assembly of FIG. 1 including a burner, a fuel valve forproviding fuel to the burner, a blower for providing air to the burner,and a controller configured to control the air and the fuel provided tothe burner;

FIG. 3 is a perspective view an alternative prior art embodiment of aradiant heating assembly including an elongated heat exchanger and ahousing, with the prior art baffles inserted into the heating tube, asshown in cross-section;

FIG. 4 is a cross-sectional view along line 4-4 of FIG. 3;

FIG. 5 is an elevated view of a prior art baffle separate from theradiant heating assembly;

FIG. 6 is a perspective view of a radiant heating assembly of thepresent invention including a housing and an elongated heat exchanger orburner tube with the integrated baffle tube of the present inventionuseable with the assembly of FIG. 2;

FIGS. 7A, 7B, and 7C are various perspective views demonstrating theheat exchanger or burner tube of the present invention having integratedbaffles as indicated;

FIGS. 8A and 8B are detailed drawings of a heat exchanger or burner tubehaving the integrated baffles of the present invention;

FIG. 8C is an end view of a burner tube demonstrating some baffles ofthe present invention in the burner tube;

FIGS. 9, 10 and 11 are perspective views of an alternative embodiment ofa radiant heating assembly including a housing and an elongated heatexchanger or burner tube;

FIG. 12A, 12B, and 12C are various perspective views demonstrating theheat exchanger or burner tube having dimples or depressions as indicatedin the device of FIGS. 9-11; and

FIG. 13 is a detailed drawing of a heat exchanger or burner tube havingthe integrated baffles of the present invention used with the device ofFIGS. 9-11.

DETAILED DESCRIPTION

Referring to the Figures, wherein like numerals indicate like partsthroughout the several views, a radiant heating assembly is generallyshown at 10. As shown in FIG. 1, the radiant heating assembly 10 istypically suspended above an area to heat the area. The radiant heatingassembly 10 may be installed in the interior or the exterior of any typeof building or structure, such as a restaurant, factory, warehouse,arena, etc. Alternatively, the radiant heating assembly 10 may beindependently suspended above any area such as a patio, and the like.

The radiant heating assembly 10 may include a housing 12 foraccommodating various components of the radiant heating assembly 10. Thehousing 12 is typically formed of sheet metal but may be formed of anytype of material without departing from the nature of the presentinvention. Furthermore, the housing 12 may have any suitableconfiguration for accommodating various components of the radiantheating assembly 10.

With reference to FIG. 2, the radiant heating assembly 10 includes aburner 14 for receiving air and fuel for combustion. The burner 14typically has an inlet 16 for receiving the air and fuel. The air andfuel are typically mixed and ignited in the burner 14. However, it is tobe appreciated that the air and fuel may be mixed before being receivedby the burner 14 according to any suitable method. The burner 14typically combusts the air and fuel into exhaust. The burner 14 mayinclude an outlet 18 for emitting exhaust generated by combustion of theair and fuel. Optionally, the radiant heating assembly 10 may include aplurality of burners 14. The burner 14 may have a venturi configurationbut alternatively may have other configurations without departing fromthe nature of the present invention. The burner 14 is typically disposedat least partially within the housing 12.

The radiant heating assembly 10 includes an elongated heat exchanger orburner tube 20 in communication with the burner 14. The elongated heatexchanger 20 typically has an inlet 22 for receiving the exhaust emittedby the outlet 18 of the burner 14. The burner 14 may be positionedadjacent the inlet 22 of the elongated heat exchanger 20. The exhaustemitted by the outlet 18 of the burner 14 passes through and heats theelongated heat exchanger 20 such that the elongated heat exchanger 20emits radiant heat. The elongated heat exchanger or burner tube 20 maybe coupled to the housing 12 at one end. The elongated heat exchanger 20may include a vent cap at another end to vent the exhaust passingthrough the elongated heat exchanger 20. Generally, the elongated heatexchanger 20 is mounted below a reflector 24 covering a significantportion of a length of the elongated heat exchanger 20. The reflector 24directs radiant heat in a directional path towards the area to be heatedto optimize the pattern of radiant heat emitted by the elongated heatexchanger 20.

The elongated heat exchanger or burner tube 20 may have various lengthsand shapes. Typically, the elongated heat exchanger 20 has a circularcross-section. However, the elongated heat exchanger 20 may have othercross-sections such as a rectangular cross-section, and the like. Theelongated heat exchanger 20 may extend in any suitable path, such as astraight path, an L-shaped path, a U-shaped path, and the like.Additionally, the radiant heating assembly 10 may include a plurality ofelongated heat exchangers 20 for receiving exhaust emitted by one or aplurality of burners 14.

The radiant heating assembly 10 includes a fuel valve 26 for providingthe fuel to the burner 16. The fuel valve 26 may provide fuel directlyto the inlet 16 of the burner 14. Alternatively, the fuel valve 26 mayprovide the fuel indirectly to the burner 14. For example, the fuelvalve 26 may pass the fuel through a pre-mixing chamber before enteringthe burner 14. As illustrated at step 28 of FIG. 6, the fuel is providedto the fuel valve 26. Typically, the fuel valve 26 is coupled to a fuelsource 30 which provides the fuel to the fuel valve 26. The fuel may benatural gas, although any suitable fuel, such as propane, may bereceived by the fuel valve 26. The fuel valve 26 may be disposed withinthe housing 12.

The fuel valve 26 may be configured to provide the fuel according to amodulating operation, but may also be supplied without modulatingoperation. With respect to the fuel valve 26, the term “modulating,” ismeant generally to describe operating the fuel valve 26 according to anygiven one of a plurality of fuel input rates defined within apredetermined range of fuel input rates. In the modulating operation,the fuel valve 26 may provide the fuel to the burner 14 according to oneof the plurality of fuel input rates. It is to be appreciated that thefuel input rate may correspond to any suitable unit of measurement. Thefuel valve 26 is generally capable of allowing from 0% to 100% of thefuel provided to the fuel valve 26 to pass to the burner 14. Saiddifferently, the fuel valve 26 is capable of opening between 0% and 100%to provide various amounts of the fuel to the burner 14.

The radiant heating assembly 10 includes a blower 32 for providing theair to the burner 14. The blower 32 may receive the air and provide theair directly to the inlet 16 of the burner 14. Alternatively, the blower32 may provide the air indirectly to the burner 14. For example, theblower 32 may pass the air through a pre-mixing chamber before enteringthe burner 14. As illustrated at a step 34, the air is provided to theblower 32. Typically, the blower 32 receives the air from an air source36 such as ambient air. In particular, the blower 32 may draw the airthrough an aperture 38 defined in the housing 12 before providing theair to the burner 14. The blower 32 may be disposed within the housing12 and in fluid communication with the elongated heat exchanger 20 forforcing the exhaust through the elongated heat exchanger 20.

In one embodiment, the blower 32 may force the air through the burner 14and the exhaust through the elongated heat exchanger 20 by expelling theair away from the blower 32. Alternatively, the blower 32 may force theair through the burner 14 and the exhaust through the elongated heatexchanger 20 by pulling the air towards the blower 32.

As with the fuel valve 26, the blower 32 is may be configured to providethe air according to a modulating operation, or may supplied with nomodulation whatsoever. With respect to the blower 32, the term“modulating,” is meant generally to describe operating the blower 32according to any given one of a plurality of blower input rates definedwithin a predetermined range of blower input rates. The blower 32typically includes a variable speed motor capable of providing the airat various rates. More specifically, the variable speed motor may be anelectrically commutated motor or a permanent split capacitor motor. Theblower 32 is generally capable of operating between 0 and 10,000 RPM.However, it is to be appreciated that the blower 32 may operate in anyother suitable range. In the modulating operation, the blower 32 mayprovide the air to the burner 14 according to one of the plurality ofblower input rates, as will be described below. The blower input ratemay correspond to any suitable unit of measurement. For example, theblower input rate may correspond to a pressure differential measured atone or more locations within the blower 32, the burner 14, and theelongated heat exchanger 20, and the like. Specifically, the radiantheating assembly 10 may include a pressure sensor 39 for measuring thepressure differential and for providing a signal corresponding to thepressure differential measured.

As shown in FIGS. 2 and 4, the radiant heating assembly 10 includes acontroller 40 configured to control the amount of the air and the fuelprovided to the burner 14 by modulating at least one of the fuel valve26 and the blower 32. The controller 40 may include a processing unit,such as a microcontroller for receiving inputs and processing andexecuting commands. Furthermore, the controller 40 may include logic,such as PID logic, and memory for monitoring information on past on/offheating cycles and optimizing on/off heating cycles based on themonitored information for increasing efficiency of the radiant heatingassembly 10. The controller 40 may be disposed within the housing 12 andelectrically connected to the fuel valve 26 and the blower 32. However,electrical connections between the controller 40, the fuel valve 26, andthe blower 32 are generally not shown in the figures for simplicity inillustration.

The radiant heating assembly 10 may include an ignition controller 42.Typically, the ignition controller 42 is operatively connected betweenthe burner 14 and the controller 40. Furthermore, an ignitor 44 may bedisposed within or adjacent to the burner 14 for providing a flame forigniting the air and the fuel within the burner 14. The ignitor 44 maybe controlled by the ignition controller 42. In addition, a flame sensormay be disposed adjacent the burner 14 for monitoring the flame withinthe burner 14. The ignition controller 42 regulates the flame providedby the ignitor 44 according to signals provided by the flame sensor. Theignition controller 42 is typically mounted in the housing 12. Theignition controller 42 may be configured to provide ignition sequencingand safety lock-out operations for the radiant heating assembly 10.

The controller 40 modulates the fuel valve 26 generally by providing afuel control signal to the fuel valve 26 and varying the fuel controlsignal. More specifically, a waveform of the fuel control signal isvaried as the fuel control signal is provided to the fuel valve 26. Thefuel valve 26 varies fuel provided to the burner 14 according tovariations of the waveform of the fuel control signal. The controller 40may be configured to modulate the fuel valve 26 according to one of theplurality of fuel input rates. As such, in the modulation operation, thecontroller 40 electrically commands the fuel valve 26 to provide thefuel to the burner 14 according to one of the plurality of fuel inputrates.

The controller 40 modulates the blower 32 generally by providing ablower control signal to the blower 32 and varying the blower controlsignal. In particular, a waveform of the blower control signal is variedas the blower control signal is provided to the blower 32. The blower 32varies the air provided to the burner 14 according to variations of thewaveform of the blower control signal. The controller 40 may beconfigured to modulate the blower 32 according to one of the pluralityof blower input rates. Thus, in the modulation operation, the controller40 electrically commands the blower 32 to provide the air to the burner14 according to one of the plurality of blower input rates.

In some instances, the controller 40 may modulate the fuel valve 26independent of the blower 32. That is, the controller 40 may provide thefuel control signal to the fuel valve 26 before or after providing theblower control signal to the blower 32. Similarly, the controller 40 mayvary the fuel control signal before or after varying the blower controlsignal.

Alternatively, the controller 40 may simultaneously modulate the fuelvalve 26 and the blower 32. Specifically, the controller 40 may providethe fuel control signal to the fuel valve 26 simultaneously whileproviding the blower control signal to the blower 32. Moreover, thecontroller 40 may vary the fuel control signal simultaneously whilevarying the blower control signal.

In such an environment, baffle tubes 62 as shown in FIG. 5 have beenused and inserted in the heat exchanger or burner tube 100, as shown insection in FIG. 3. Similar baffle tubes can be inserted in the burnertube 20 or FIG. 1 in a similar manner. Like any separate part, there isconcern as to the manufacture of the part, the assembly of the part (andthe accuracy thereof), the function of the part and control of anychanges to the part. What is shown as a baffle 62 in FIGS. 3 and 5 is a33 inch by 4 inch standard interlocking baffle, Detroit Radiant partnumber 60366767.

Those concerns have been found here to be managed by providing thefunctionality of a baffle integrated into the surface metal of the heatexchanger or burner tube 20, 100, 200 forming the tubular structure. Theinvention may be used with anything from the most basic burner tube orheat exchange connected an on/off radiant heater to the most complexfunctionality of burner heat exchange unit with multiple or variedmodulation, and have advantages in whatever configuration it is used. Itmay also be customized for specific applications.

Referring to FIG. 6, a perspective view of a radiant heating assembly ofthe present invention including a housing 12 and an elongated heatexchanger or burner tube 100 with the integrated depression 82, 84forming baffles 80 is shown useable with the assembly 10 of FIGS. 1 and2. A radiant reflector 24 can be placed along the length of the heatexchanger or burner tube 100 throughout the length of the tube 100, suchas in FIG. 1, but is shown covering only a portion thereof in FIG. 6.FIG. 7A demonstrates the cross-sectional configuration where the baffles80 mate or pair depressions 82, 84 to be spaced along the length of athree inch wide tube 120 inches in length for the heat exchanger orburner tube 100. Alternately, the depressions 82, 84 forming the baffles80 can be staggered with spacing from one another or otherwise staggeredto overlap or not overlap, as desired for specific applications. FIGS.7A, 7B, 7C, and 7D are various perspective views demonstrating theburner tube 100 of the present invention having integrated depressions82, 84 to form baffles 80 as indicated. FIGS. 8A and 8B are detaileddrawings of a heat exchanger or burner tube 100 having the integrateddepressions 82, 84 to form baffles 80 of the present invention at spacedintervals as shown. FIG. 8C is an end view of a burner tube 100demonstrating some depressions 82, 84 forming baffles 80 as implementedinto the heat exchanger or burner tube 100.

FIGS. 9, 10 and 11 are perspective views of an alternative embodiment ofa radiant heating assembly 10 including a housing 12 and an elongatedheat exchanger or burner tube 200 in what is commonly called a brooder.FIGS. 12A, 12B, and 12C are various perspective views demonstrating theheat exchanger or burner tube 200 having integrated depressions 82, 84forming baffles 80 as focused and shown. FIG. 13 is a detailed drawingof a heat exchanger or burner tube 200 having the integrated depressions82, 84 forming baffles 80 for a device as shown in FIGS. 9, 10 and 11.

The invention has been described in an illustrative manner, and it is tobe understood that the terminology which has been used is intended to bein the nature of words of description rather than of limitation. Manymodifications and variations of the present invention are possible inlight of the above teachings, and the invention may be practicedotherwise than as specifically described.

What is claimed is:
 1. A radiant heater having an elongated heatexchanger in communication with a burner including baffle elementsintegrated into the heat exchanger externally of the heat exchanger toprovide baffling internal to the heat exchanger.
 2. A system toradiantly heat an area comprising a burner and a burner tube incommunication with said burner, further comprising depressions in thewall of said burner tube to form baffles.
 3. A radiant heating assemblycomprising: a burner for receiving air and fuel for combustion; anelongated heat exchanger in communication with said burner includingbaffle elements integrated into the heat exchanger; a fuel valve forproviding the fuel to said burner; a blower for providing the air tosaid burner; and a controller configured to control the amount of theair and the fuel provided to said burner;
 4. An assembly in accordancewith claim 3, wherein the heat exchanger comprises a U-shaped tube. 5.An assembly in accordance with claim 3, wherein the heat exchangercomprises a single straight tube.
 6. A demand radiant heating systemcomprising: an elongated radiant heating tube having an inlet end and anexhaust end, further comprising depressions in the wall of the heatingtube to form baffles internally within the heating tube; a burner tubeconnected to said inlet end of said radiant heating tube; a housingdefining an air tight compartment connected to said burner tube, ablower for continually forcing air into said air tight compartment; aburner at least partially disposed in said burner tube, said burnerhaving an inlet end to receive air and fuel, means for mixing air andfuel, and an exit end for emitting the air/fuel mixture for combustionclosely adjacent thereto; and single fuel means disposed in said airtight compartment and operatively connected to said inlet end of saidburner for providing regulation of fuel to said burner at a plurality ofpredetermined pressures for demand heating, whereby fuel and air ismixed and burned by said burner to heat said radiant heating tube andexhaust gases exit said exhaust end; and temperature means connected tosaid fuel means for triggering said predetermined pressures at aplurality of temperature settings.
 7. A heater comprising: a burnerhousing having a front panel and an inlet for supplying air into saidburner housing; a plurality of burners spaced from each other in saidburner housing for combusting a fuel and air mixture into heated gas; aplurality of heater tubes each extending from and returning to saidfront panel of said burner housing for radiating heat, said heater tubeseach having an inlet end and an outlet end with said inlet ends incommunication with said burners for receiving the heated gas from saidburners and having depressions in the wall of each of said heater tubesto form internal baffles, a collector box disposed in said burnerhousing in communication with said outlet ends of said heater tubes forreceiving the heated gas from said heater tubes; and a fan incommunication with said collector box to move the heated gas from saidburners to said collector box; said outlet ends of said heater tubesbeing adjacent each other at said burner housing and each of said inletends of said heater tubes being spaced in different directions from saidoutlet ends at said front panel of said burner housing.